Download Watkiss Automation OCE BLM500 User manual

User manual
BLM 500 / Bookletmaker 50
Operating information
Copyright
Copyright

2008 Océ
All rights reserved. No part of this work may be reproduced, copied, adapted, or
transmitted in any form or by any means without written permission from Océ.
Océ makes no representation or warranties with respect to the contents hereof and
specifically disclaims any implied warranties of merchantability or fitness for any
particular purpose.
Further, Océ reserves the right to revise this publication and to make changes from
time to time in the content hereof without obligation to notify any person of such
revision or changes.
Note: The contents of this document are subject to copyright
protection by third parties.
Edition 2008-08
US
Table of Contents
Table of Contents
Chapter 1
Introduction to the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description of the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Right-Hand Side of the Booklet maker. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
The Rear Panel of the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2
How to run the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn ON the Booklet maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enter the Job Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacker adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
13
14
17
18
Chapter 3
The User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Job Mimic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The BASIC Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The LOAD & SAVE Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The ADVANCED Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The CONFIGURE Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The MENU Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
20
23
25
27
29
30
31
Chapter 4
Standard Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load and Save the Job Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust the Stitch Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open the Connecting Bridge Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open and Close the Folder Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift and Lower the Clincher Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open the Gathering Area Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift the Booklet maker Main Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Empty the Trim Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open the Stitch Wire Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust the Stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operate the Booklet maker offline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
34
35
36
37
38
40
41
43
44
45
47
3
Table of Contents
Chapter 5
Error Conditions, Problems, and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear a Printer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear a Booklet maker error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Book Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stitch Timeout Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stitch Head Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear a Stitch Wire Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clear a Stitch Head Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibrate the Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manually park the Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
50
51
52
54
63
68
75
76
77
80
84
85
86
Chapter 6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
About Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Booklet maker cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Clean the Static Elimination Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Clean the Former Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Clean the Polyurethane Strips in the Form Clamp . . . . . . . . . . . . . . . . . . 96
Clean the Trimmings Removal Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Clean excess grease from the Stitch Head . . . . . . . . . . . . . . . . . . . . . . 101
Lubricate the Stitch Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Lubricate the Wire-feed Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Install New Stitch Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Appendix A
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Appendix B
Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4
Chapter 1
Introduction to the Booklet
maker
5
Introduction
Introduction
Introduction
Thank you for choosing the Booklet maker.
Your Manual
The User Manual for the Booklet maker describes how to perform these tasks:
■ Operate the Booklet maker
■ Find and correct error conditions
■ Perform normal maintenance tasks
Operator training is given when the Booklet maker is installed. To make sure you use
your Booklet maker correctly, read your manual.
The User Manual for the Booklet maker does not describe the operation of the
printer. If needed, refer to your printer user manual.
Safety Information
Safety information is included in the separate “Safety Information Manual.” Read
the safety information before you use your Booklet maker.
Caution: A CAUTION message tells you that a procedure or operation can
be dangerous. To prevent injury, you must follow the instructions.
Attention: An ATTENTION message tells you that a procedure or operation can
damage the machine or the product. To prevent damage, you must follow the
instructions.
Installation
Your Booklet maker must be installed by a service engineer. Special knowledge is
needed to install the machine.
Attention:
Connect the machine only to a power supply of the correct voltage with a good
ground connection. The correct machine voltage is shown on the label at the power
supply input on the rear of the machine. If the machine is connected to the wrong
supply, the warranty is voided.
6
Chapter 1 Introduction to the Booklet maker
Introduction
How to Get Help
If you have any questions or problems, refer to the problem-solving section in this
manual (see the chapter “Error Conditions, Problems, and Solutions”). Contact your
Booklet maker supplier for further help.
7
Description of the Booklet maker
Description of the Booklet maker
Introduction
The Booklet maker operates online with digital printers to process sets of printed
pages into stitched books. The main parts are shown below.
Illustration
[1]
A
B
C
D
[1] Operator Side of the Booklet maker
Component - function table
[1]
[1] Operator Side of the Booklet maker
8
Component
Function
A
The connecting
bridge
The connecting bridge moves the printed sheets from
the printer to the Booklet maker. If needed, the sheets
are rotated into the correct direction. Rotation lets the
printer operate at optimum print speed. Adjustment
for the size of the paper and sheet rotation is
automatic, according to the settings entered on the
touch screen.
B
The user interface
The user interface has a color touch screen, a start
button, and a stop button.
C
The Booklet
maker
The Booklet maker stitches, folds, spine-forms, and
trims the sheets to make a finished book.
D
The stacker
The stacker collects the finished books.
Chapter 1 Introduction to the Booklet maker
Right-Hand Side of the Booklet maker
Right-Hand Side of the Booklet maker
Illustration
[2]
A
B
[2] Right-hand side of the Booklet maker
Component - function table
[2]
[2] Right-hand side of the Booklet maker
Component
Function
A
The stitch-wire
cabinet
The stitch-wire cabinet holds the spool of
stitch-wire.
B
Trim Bin
The trim bin collects the paper that is trimmed from
the edge of the book
9
The Rear Panel of the Booklet maker
The Rear Panel of the Booklet maker
Illustration
[3]
A
B
C
D
E
F
[3] The Rear Panel of the Booklet maker
Component - function table
[3]
[3] The Rear Panel of the Booklet maker
10
Component
Function
A
Rating and serial
label
The rating label displays the type of machine, serial
number, power use, and fuse information.
B
Power ON/OFF
switch
The power ON/OFF switch turns the Booklet
maker ON or OFF. When you turn OFF the Booklet
maker, the current settings are stored.
C
Voltage advisory
label
The voltage advisory label tells the installer to refer
to the installation instructions before the Booklet
maker is connected to the electrical power supply.
The Booklet maker can be adjusted for one of
several different input voltages.
D
Fuses
The fuses make sure the operator and the machine
are protected if there is an electrical problem or
short circuit.
E
Voltage label
The voltage label is fitted to the Booklet maker
during the installation procedure. The voltage label
displays the selected voltage.
F
Power input
connector
The power input connector is used to connect the
Booklet maker to the electrical power supply.
Chapter 1 Introduction to the Booklet maker
Chapter 2
How to run the Booklet maker
This chapter gives information on how to run a job on the Booklet maker. For
information on how to operate the printer, refer to the printer documentation.
Information about the user interface is included in the chapter “The User Interface.”
Information about standard procedures, for example opening covers to clear a paper
jam, is included in the chapter “Standard Tasks.”
11
Before You Begin
Before You Begin
Paper and Book Quality Instructions
■
■
■
■
■
The size of paper and the thickness of the set must be measured. These
measurements are entered via the touch screen before you begin a print job.
Measure the size of the printed paper. The paper dimension changes when the
paper is printed.
Measure the set thickness as accurately as possible. Use the measuring tool
supplied with the machine.
Enter accurate dimensions via the touch screen.
If the book is made from several different types of paper, make sure the different
paper types are all the same size.
See Book Quality on page 63 for further information.
12
Chapter 2 How to run the Booklet maker
Turn ON the Booklet maker
Turn ON the Booklet maker
Procedure
1. Connect the Booklet maker to the power supply.
2. Use the ON/OFF switch to turn ON the Booklet maker.
Result
The machine makes this sequence of beeps:
'beep__beep beep beep beep_____ beep beep'.
The touch screen illuminates and the machine is ready for use.
13
Enter the Job Settings
Enter the Job Settings
Introduction
Enter the settings for a new job in the BASIC window on the touch screen. See the
chapter “The User Interface” for more information.
The PAPER SIZE and PAGE DIRECTION settings are entered on the touch screen.
These dimensions refer to the format of the paper when it enters the Booklet maker.
Attention: Do not operate the touch screen with a sharp object or with too much
force. These actions can damage the touch screen.
Before You Begin
[4]
Step
Action
1
Print a set to the
stacker.
2
Measure the sheet
size and the set
thickness.
3
Use these
dimensions for the
job setting.
Information
Measure the set accurately. To make an accurate
book you must enter accurate paper dimensions via
the touch screen.
Note: This set can be made into a book (see Operate the Booklet maker offline on
page 47).
14
Chapter 2 How to run the Booklet maker
Enter the Job Settings
Procedure for a New Job
[5]
Step
Action
Information
1
Touch BASIC
2
Enter the paper
size
Touch PAPER SIZE. Enter the dimensions of the
paper.
The job setting is easier if you first select a preset
paper size, then adjust the settings as necessary
Touch PAPER SIZE > PRESETS > A3 or A4. (USA:
11x17, 8.5x11 or 8.5x14)
3
Enter the page
direction
Touch PAGE DIRECTION > LANDSCAPE or
PORTRAIT.
If the PAGE DIRECTION option is not available, the
PAGE DIRECTION cannot be changed.
4
Enter the page
rotation setting
For A4 paper size, the normal setting for ROTATE is
ON. Rotation lets the printer operate at optimum
speed.
Touch ROTATE to turn the sheet rotation ON or OFF.
Always select the page direction before you change
the rotate setting.
5
Enter the set
thickness.
Touch SET THICKNESS. Enter the measured value.
6
Enter the number
of stitches.
Touch STITCHES and enter the number of stitches.
If needed, the stitch pitch can be changed. See
"STITCH PITCH," table 9 on page 25
7
Enter the spine
form setting
The spine form setting is automatic, according to the
SET THICKNESS setting. If needed, the setting can
be changed. See "FORM" in table 9 on page 25
8
Enter the trim
setting.
The trim setting is automatic, according to the PAGE
SIZE and SET THICKNESS settings. To change the
setting, touch TRIM. See “TRIM” in table 10 on
page 27
9
Touch CLOSE
If needed, save the If the same job settings are used frequently, then save
job settings to
the job settings to memory.
memory.
See "Save a job."Load and Save the Job Settings on
page 34
Procedure for a Saved Job
1. Touch LOAD & SAVE
15
Enter the Job Settings
2. Touch the job name or use the Up arrow or the Down arrow to select the job.
3. Touch LOAD.
4. Wait until the Booklet maker is ready
16
Chapter 2 How to run the Booklet maker
Stacker adjustment
Stacker adjustment
Adjust the Stacker
Adjust the stacker according to the size and thickness of the finished bookAdjust the
Stacker on page 45.
17
Run the Job
Run the Job
1. Make sure the adjustments on the Booklet maker are complete before you release the
print job from the print queue.
2. Start the print job. The Booklet maker starts automatically.
3. Check the quality of the first book.
4. If the quality is not acceptable, make adjustments (see ‘Book Quality’ on page 63).
Result
During the job
■ Unload books from the stacker before the stacker is full. The Booklet maker stops
and displays a message if the stacker is full.
■ Empty the trim bin from time to time. The Booklet maker displays a message if
the trim bin is full (see ‘Empty the Trim Bin’ on page 43).
18
Chapter 2 How to run the Booklet maker
Chapter 3
The User Interface
19
The Touch Screen
The Touch Screen
Introduction
[4]
A
B
C
[4] The User Interface
[6]
A
START Button
B
STOP Button
C
Touch Screen
The user interface includes a color touch screen and START/STOP buttons.
Operate the touch screen with your fingertip. You can touch the screen with a blunt
item, for example a palm-top 'wand' or the blunt end of a pen. Do not use too much
force. A light touch is all that is needed.
Power save
The touch screen has a power-save function. After several minutes without use, the
brightness of the touch screen decreases. After several hours, the touch screen turns
off. Touch the screen to restore the normal brightness. The touch screen takes two or
three minutes to reach full brightness.
If you hear a 'beep' when you operate the touch screen, the selected function is not
available. Some functions are not available when the machine is in operation.
Some functions and buttons are only available at certain access levels. See "ACCESS
LEVEL" The MENU Window on page 31.
Attention: Do not operate the touch screen with a sharp object or with too much
force. These actions can damage the touch screen.
20
Chapter 3 The User Interface
The Touch Screen
Illustration
[5]
6
5
7
8
3
4
2
1
[5] The Touch Screen
Component - function table
[7]
No.
Component
Function
1
Window Tabs
The touch screen buttons are divided into groups
that have related functions. Each group of
buttons has a separate window. Touch the correct
tab to select the window.
LOAD & SAVE
BASIC
ADVANCED
CONFIGURE
MENU
2
Window Buttons
Each window contains a group of buttons. Touch
the button to select the function.
3
Message List
Information and error messages are shown in the
MESSAGE LIST. To display the information
about a message, touch HELP then touch the
message list.
4
Job Mimic
The job mimic shows the current machine
settings.
21
The Touch Screen
No.
Component
Function
5
Status
The STATUS line shows the machine status.
- GREEN
The Booklet maker is READY or RUNNING.
- ORANGE
PLEASE WAIT - wait until the Booklet maker
is ready. ATTENTION - the Booklet maker
needs intervention by the operator.
- RED
The Booklet maker is in an ERROR condition.
6
Help
Help text is available on the touch screen.
Touch HELP then touch any button or tab on
the screen. Information about that button or
tab is displayed.
■ Use the Up arrow and the Down arrow to
scroll up and down the screen.
■ Some text has more than one screen. Use the
right arrow and left arrow to see the other
screens.
■
To leave the help text, touch HELP or touch X.
22
7
Sheet Counter
The sheet counter shows the number of sheets in
the gathering area. The counter starts again with
each book.
8
Book Counter
The book counter shows the number of books
made. The counter is reset to zero when the
Booklet maker is turned off.
Chapter 3 The User Interface
The Job Mimic
The Job Mimic
Introduction
The job mimic shows the current machine status.
Illustration
[6]
[6] The Job Mimic
Component - function table
[8]
No.
1
Icon
[7]
2
The following items are shown
■ the size of paper
■ the format of the paper in the
gathering area
■ the broken line shows the fold
line
■ the small thick lines show the
stitches
■ the arrow shows the original
feed edge in the printer
Stitch Pitch
[8]
3
[9]
Information
The stitch pitch is shown only when
a non-standard setting is selected.
The set thickness, in mm, is shown.
23
The Job Mimic
No.
4
5
24
Icon
[10]
[11]
Chapter 3 The User Interface
Information
The number of forms is shown. If
the pressure is adjusted, the setting
is shown in brackets. A red X shows
that the form function is not active.
The trim setting is displayed. A red
X shows that the trim function is not
active.
The BASIC Window
The BASIC Window
Introduction
The BASIC
window gives you access to frequently-changed machine settings.
Button overview
[9]
[9] The BASIC Window Buttons
(1 – 2)
Button
Information
PAPER SIZE
Measure the accurate size of the paper before you make
a book.
Touch PAPER SIZE to enter the paper size. When the
machine is in operation, you can adjust the PAPER
SIZE by a maximum of +/- 1 mm.
- PAGE DIRECTION
Touch PAGE DIRECTION to change the direction of
the paper to Landscape or Portrait.
- ROTATE
Touch ROTATE to set the sheet rotation ON or OFF. If
you select A4 portrait (USA: 8.5x11), ROTATE is set to
ON automatically.
- PRESETS
Touch PRESET to select a standard paper size.
SET THICKNESS
Use the SET THICKNESS window to define the
thickness of the set.
Measure the thickness of the set before you make a book.
Touch SET THICKNESS and enter the value.
STITCHES
Touch STITCHES to select the number of stitches.
Available options are 1 - 6. The machine automatically
calculates the position of the stitches according to the
size of the paper. Select 0 to turn off the stitch function.
- STITCH PITCH
The stitch pitch is the space between the stitches. The
machine automatically calculates the stitch pitch
according to the size of the paper.
If a non-standard stitch pitch is needed, use STITCH
PITCH to make the adjustment.
- AUTO
Touch AUTO to select the default stitch pitch.
25
The BASIC Window
[9] The BASIC Window Buttons
(2 – 2)
Button
Information
FORM
To make the square spine of the book, pressure is applied
to the spine. This process is called forming. Touch
FORM to specify the amount of spine form. To make a
good spine on different paper types, the amount of spine
form can be changed.
To change the amount of spine form
■ Touch NUMBER to change how many times the
spine is processed
■ Touch PRESSURE to change the pressure
26
- AUTO
Touch AUTO to select the optimum amount of spine
form, according to the set thickness.
- NUMBER
Touch NUMBER to select how many times the form
roller processes the spine. The available options are 1, 2,
3, or 4. The form function can be turned off. An increase
in NUMBER increases the time taken to form the spine
and can decrease the production rate for thin books.
Alternatively, increase the PRESSURE.
- PRESSURE
Touch PRESSURE to increase or decrease the pressure
used to form the spine. Touch + to increase the amount of
spine form. Touch - to decrease the amount of spine form.
The range is -9 to +9. The default setting is 0.
- THRESHOLD
The square spine is formed only on sets thicker than 0.8
mm. To change this value, touch THRESHOLD and
enter the value you need. The maximum value is 1.5 mm.
TRIM
The trim dimension is calculated automatically
according to the PAPER SIZE and SET THICKNESS.
If needed, the trim dimension can be changed. Touch
TRIM to adjust the size of the finished book after the
fore-edge is trimmed. The maximum trim is 28 mm. The
trim function can be turned off.
- AUTO
Touch AUTO to select the default trim position.
Chapter 3 The User Interface
The LOAD & SAVE Window
The LOAD & SAVE Window
Introduction
The LOAD & SAVE
window lets you save and reload job settings. Each job is
given a name. The jobs are displayed in a list on the screen. Touch the job name or
use the Up arrow or Down arrow to make the selection.
Button overview
[10]
[10] The LOAD & SAVE Window Buttons
(1 – 2)
Button
Information
SAVE
Touch SAVE to save the current settings. An on-screen
keyboard is displayed. Enter the job name. Touch OK or
CLOSE. The new job appears in the list of saved jobs.
You can reload a saved job to decrease set-up time in the
future.
- REPLACE
If you change the settings of a saved job, touch
REPLACE to save the new settings.
- CANCEL
Touch CANCEL if you do not need to save a job that you
have changed.
- SAVE NEW
If you change the settings of a saved job, touch SAVE
NEW to save the new settings as a new job. An on-screen
keyboard is displayed. Enter the new job name. Touch
OK or CLOSE. The original job is not changed. If the
job name is not changed before OK or CLOSE is
touched, the job will be saved with the current name
followed by an asterisk *.
JOB DETAILS
JOB DETAILS shows the settings for each saved job.
Select the job that you need to view from the job list.
Touch JOB DETAILS to see a summary of the job
settings.
LOAD
Touch the job name or use the Up arrow or the Down
arrow to make the selection. Touch the LOAD button
27
The LOAD & SAVE Window
[10] The LOAD & SAVE Window Buttons
(2 – 2)
Button
Information
PADLOCK
SYMBOL
The padlock symbol shows when a saved job is locked or
unlocked. There is a small padlock symbol next to each
locked job. To lock or unlock a job.
1. select the job from the job list
2. touch the large key symbol.
A padlock symbol displayed in light grey shows that a
job has been locked by a supervisor to prevent changes to
the settings
DELETE
To delete a particular job it must be unlocked. Touch the
job name or use the Up arrow or Down arrow to make the
selection from the job list. Touch and hold DELETE. A
red line appears. The red line fills from left to right. Hold
DELETE until the red line reaches the right-hand side.
VIEW OF JOB LIST VIEW OF JOB LIST changes the order that saved jobs
are listed. There is a line between Factory Template jobs
and jobs saved by the operator. The Factory Template
jobs are at the top of the list
28
- A->Z
Touch A->Z to list the jobs in alphabetical order.
- BY USE
Touch BY USE to list jobs in the order they were last
used. The most recently-run job is at the top of the list.
- BY INDEX
Touch BY INDEX to list jobs in numerical order. the
machine gives a number to all jobs that are saved.
Chapter 3 The User Interface
The ADVANCED Window
The ADVANCED Window
Introduction
The ADVANCED
window gives you access to special machine functions.
[11]
[11] Button overview
Button
Information
RE-REF
If the machine calibration appears incorrect or if an 'axis
moving' error message remains on the screen, touch
RE-REF to re-reference the adjustment axes. The
adjustment axes return to the current settings. At
intervals, the machine will re-reference the axes during
the set-up procedure.
STITCHER UP
Touch STITCHER UP before you lubricate the stitch
head. This action moves the stitch head to the correct
position for lubrication.
PURGE SET
When an error occurs, a set or part of a set can remain in
the gathering area. Touch START , then touch PURGE
SET to clear the set from the machine. The book is not
stitched or trimmed
According to the type of error that occurred, there can be
a pause of 7 seconds before the PURGE SET button will
operate.
- MAKE BOOK
When an error occurs, a set or part of a set can remain in
the gathering area. Touch START then touch MAKE
BOOK to clear the set from the machine. The book is not
stitched or trimmed.
According to the type of error that occurred, there can be
a pause of 7 seconds before the MAKE BOOK button
will operate.
29
The CONFIGURE Window
The CONFIGURE Window
Introduction
The CONFIGURE
machine.
window lets you make changes to the configuration of the
Some functions and buttons are only available at certain access levels, see 'ACCESS
LEVEL' table 13 on page 31.
CONFIGURE Window Buttons
[12]
[12] Button overview
Button
Information
Supervisor
Access
MACHINE
OPTIONS
Touch MACHINE OPTIONS to view the
general machine setup. Some of the settings
can be changed, depending on the current
access level.
Yes
MEASUREM
ENT
Select 'mm' or 'inch' as the unit of
measurement.
Yes
- STITCH
SENSOR
There is a sensor that checks for stitches.
Touch STITCH SENSOR to turn the stitch
sensor on or off. The default setting is ON.
Yes
- PRESET
The preset paper sizes can be either ISO A
Yes
PAPER SIZES sizes or US paper sizes. To select which preset
paper sizes are available, touch the relevant
button.
30
NETWORK
SETTINGS
This button is used by the service engineer.
SHUTTLE
Touch SHUTTLE to make adjustments to the Yes
tamper.
-TAMPER
DELAY
This button is used by the service engineer.
- TAMPER
TIME
TAMPER TIME adjusts the time that the
Yes
tamper touches the set.
An increase in TAMPER TIME causes a
decrease in the production rate for thin books.
FORM
SETUP
This button is used by the service engineer.
Chapter 3 The User Interface
No
View only
View only
The MENU Window
The MENU Window
Introduction
MENU
shows the settings that are not changed during day-to-day operation.
These settings include
■ Change the Access Level
■ Change the display language
■ Advanced machine settings that are accessed by a person who has the correct
access-code.
Button overview
[13]
[13] The MENU Window Buttons
Button
Information
ACCESS LEVEL
The Touch Screen has five different access levels
■ Operator
■ Supervisor
■ Service
■ Distributor
■ Factory
(1 – 2)
Touch ACCESS LEVEL and select the correct level
from the list. The last three levels are protected by access
codes. To protect job settings, the supervisor level allows
jobs to be locked.
CURRENT
LANGUAGE
Touch one of the flags to select the language you need.
AXES
Touch AXES to re-reference individual axes. Supervisor
access level is needed for this function.
Other functions on this button are used by the service
engineer.
BRIDGE
Touch BRIDGE to re-reference the bridge axes.
Supervisor access level is needed for this function.
Other functions on this button are used by the service
engineer.
SERVICE OPTIONS This button is used by the service engineer.
TEST
This button is used by the service engineer.
31
The MENU Window
[13] The MENU Window Buttons
32
(2 – 2)
Button
Information
COUNTERS
The counters display the
■ number of books that have been made
■ number of sheets that have been processed
■ number of stitches that have been used
-RESET
Touch RESET to reset the book, sheet counter, and stitch
counter.
Touch and hold RESET. A red line appears. The red line
fills from left to right. Hold RESET until the red line
reaches the right-hand side.
Chapter 3 The User Interface
Chapter 4
Standard Tasks
This chapter describes the standard tasks that are needed in the day-to-day operation
of your Booklet maker.
33
Load and Save the Job Settings
Load and Save the Job Settings
Introduction
The current job settings can be saved to memory and reloaded for use again at a later
date. Load the 'Default Job Template' to reset the Booklet maker to normal settings.
Save a job
1. Touch LOAD & SAVE
> SAVE.
2. If these options appear, select one.
■
■
■
REPLACE to over-write the previous job with the current job settings.
SAVE NEW to save the current job with a new name.
CANCEL to cancel the job save.
3. Enter the name for the job on the keyboard
4. Touch OK or CLOSE.
Load a job
1.
2.
3.
4.
Touch LOAD & SAVE .
Touch the job name or use the Up arrow or the Down arrow to select the job.
Touch LOAD.
Wait until the Booklet maker has made the adjustments.
Reset the Booklet maker to default settings
1.
2.
3.
4.
34
Touch LOAD & SAVE .
Select the Default Job Template from the list of jobs.
Touch LOAD.
Touch YES.
Chapter 4 Standard Tasks
Adjust the Stitch Pitch
Adjust the Stitch Pitch
Introduction
The stitch pitch is the space between the stitches. The machine automatically
calculates the stitch pitch according to the size of the paper and the number of
stitches. The stitches are inserted symmetrically on the spine of the book.
If a non-standard stitch pitch is needed, use STITCH PITCH to make the adjustment.
[12]
A = Stitch Pitch
A
[12] Stitch Pitch
A
B
Limitations:
■ The minimum stitch pitch 'A' is 25 mm.
■ The minimum distance from the center of the stitch to the edge of sheet 'B' is 15
mm.
When to do
If you need the Booklet maker to insert the stitches in a non-standard position. For
example, to keep the stitches away from the text on the spine of the book.
Select a non-standard stitch pitch
1. Touch BASIC > STITCHES
2. Touch AUTO. The STITCH PITCH value becomes green.
3. Change the stitch pitch value. Either use the "+" and "-" or touch the green stitch
pitch value to open a numeric keypad.
4. Touch STITCHES to close the window.
The stitch pitch value is displayed in the job mimic and on the STITCHES button.
Select a standard stitch pitch
1. Touch BASIC > STITCHES.
2. Touch AUTO to select ON.
3. Touch STITCHES to close the window.
The stitch pitch value is not displayed in the job mimic or on the STITCHES button.
35
Open the Connecting Bridge Cover
Open the Connecting Bridge Cover
Introduction
The Booklet maker will not stop if you open the connecting bridge cover.
[13]
A
[13] Connecting Bridge Cover in the open position.
[14]
A
Connecting Bridge Cover
When to do
If a machine error occurs, or for maintenance.
■ To clear a paper jam
■ To clean the static elimination bar
Caution: Keep your hands, clothing and hair away from the belts.
Procedure
Lift the connecting bridge cover.
36
Chapter 4 Standard Tasks
Open and Close the Folder Cover
Open and Close the Folder Cover
Introduction
If a machine error occurs, or for maintenance.
■ To access the stitch area
■ To access the folder area
Note: The folder cover has an interlock switch. The Booklet maker stops if you open
the folder cover.
[14]
[14] Unlock and lock the Folder Cover.
Open the Folder Cover
1. Lift the black locking handle against the spring pressure.
2. Turn the handle through 90° to unlock.
3. Lift the folder cover carefully to the vertical position.
Close the Folder Cover
Caution: Check that the folder cover will not hit the clincher frame locking
handle when you close the folder cover. If necessary, lift and rotate the
clincher frame locking handle to a new position figure 16 on page 38.
1. Lower the folder cover.
2. Turn the handle through 90° to lock.
3. Close the locking handle to lock the folder cover.
37
Lift and Lower the Clincher Frame
Lift and Lower the Clincher Frame
Introduction
[15]
A
B
[15] Folder Cover in the vertical position.
[15]
A
Folder Cover
B
Clincher Frame
[16]
A
B
C
[16] Clincher Frame Components
[16]
A
Clincher
B
Locking Handle
C
Clincher Frame
When to do
If a machine error occurs, or for maintenance.
■ To clear a paper jam in the stitch area
■ To unlock the Booklet maker main deck
38
Chapter 4 Standard Tasks
Lift and Lower the Clincher Frame
Lift the Clincher Frame
1. Open the folder cover.
2. Turn the locking handle to the left
, until the thread is disengaged.
3. Lift the clincher frame to the vertical position.
Lower the Clincher Frame
Attention: You must hold the weight of the clincher frame. Do not let the
clincher frame fall on your hand.
1. Lower the clincher frame.
2. Turn the locking handle to the right
, until the handle is tight.
3. Check that the locking handle will not be hit by the folder cover when you close the
folder cover. The locking handle should point towards the middle of the machine. If
necessary, lift and rotate the locking handle to a new position.
39
Open the Gathering Area Cover
Open the Gathering Area Cover
Introduction
[17]
A
B
C
[17] Gathering Area Cover.
[17]
A
Connecting Bridge Cover open
B
Gathering Area Cover
C
Gathering Area Cover Handle
When to do
If a machine error occurs, or for maintenance.
■ To access the gathering area
■ To access the static elimination bar in the gathering area
The Booklet maker will stop if you open the gathering area cover.
Procedure
1. Open the connecting bridge cover.
2. Use the gathering area cover handle to lift the gathering area cover.
40
Chapter 4 Standard Tasks
Lift the Booklet maker Main Deck
Lift the Booklet maker Main Deck
Introduction
[18]
A
B
C
D
E
[18] Lift the Booklet maker Main Deck
[18]
A
Folder Cover open
B
Connecting Bridge Cover open
C
Clincher Frame lifted
D
Gathering Area Cover
E
Main Deck
When to do
If a machine error occurs, or for maintenance.
■ To access the stitch head
■ To access the former area
■ To access the trim area
Procedure
Caution: Keep your hands and fingers clear when you lift the main deck.
41
Lift the Booklet maker Main Deck
[19]
42
Step
Action
Information
1
Open the connecting bridge
cover.
(see ‘Open the Connecting Bridge
Cover’ on page 36)
2
Open the folder cover.
(see ‘Open the Connecting Bridge
Cover’ on page 36)
3
Lift the clincher frame.
(see ‘Lift the Clincher Frame’ on
page 39)
4
Open the gathering area cover. (see ‘Lower the Clincher Frame’
on page 39)
5
Lift the Booklet maker main
deck.
Chapter 4 Standard Tasks
The main deck lifts to
approximately 60º. The weight of
the main deck is supported by a gas
strut. Let the gas strut control the
movement of the main deck.
Empty the Trim Bin
Empty the Trim Bin
Introduction
[19]
A
B
[19] Trim Bin Open.
[20]
A
Trim Bin Side Handle
B
Trim Bin open
Note: The Booklet maker operates with the trim bin removed for a short period of
time. The printer waits while the trim bin is removed, then continues when the trim
bin is replaced. To prevent lost production, you must remove, empty, and return the
trim bin to the Booklet maker as quickly as possible.
When to do
■
■
An error message is displayed on the touch screen when the trim bin is full.
You can empty the trim bin when you choose. For example, before you start a
print job.
Procedure
1.
2.
3.
4.
5.
Use the handle to open the trim bin.
Use the side handles to lift and remove the trim bin.
Empty the trim bin
Fit the bottom of the trim bin over the mounting rail.
Push the trim bin closed at the top.
43
Open the Stitch Wire Cabinet
Open the Stitch Wire Cabinet
Introduction
[20]
A
[20] Stitch Wire Cabinet.
[21]
A
Stitch wire cabinet open
When to do
■
■
To see if the stitch wire is jammed or finished. An error message is displayed on
the touch screen when the stitch wire is jammed or finished.
To install a new stitch wire spool. (see ‘Install New Stitch Wire’ on page 107).
Procedure
Open the stitch wire cabinet cover. The cover is held closed by a magnetic catch.
44
Chapter 4 Standard Tasks
Adjust the Stacker
Adjust the Stacker
Introduction
The collection table must be in the correct position for the stacker to operate. The
position of the collection table depends on the finished size of the job.
When you start a new job
If the books do not stack correctly
■
■
[21]
A
1
2
B
C
[21] The Stacker
[22]
A
Catch tray adjustment
B
Collection table
C
Catch tray
[22]
A
B
C
D
[22] Collection table position
45
Adjust the Stacker
[23]
A
Book size in window
B
Collection table
C
Orange plastic hand screw
D
Catch tray
Procedure
[24]
Step
Action
Information
1
Set the catch tray angle according For books that are 1.5 mm thick or
to the thickness of the book.
less, use position 1.
For books that are 1.5 mm thick or
less, use position 2.
figure 21 on page 45
2
Set the collection table position
according to the size of the book.
Read the settings through the
window.
figure 22 on page 45
These settings are recommendations. The settings can change with the size,
thickness, and material of book. Make further adjustments if necessary.
46
Chapter 4 Standard Tasks
Operate the Booklet maker offline
Operate the Booklet maker offline
Introduction
You can hand feed sets into the Booklet maker if offline operation is needed. The
machine operates when you push the two buttons.
When to do
■
■
To check the settings are correct
To make a small number of books offline
Attention: Do not put your hands in the gathering area when the machine
operates. Use two hands to push the buttons. For safety reasons, this task is for a
single operator. Do not let another person help you.
Procedure
1. Enter the correct settings on the touch screen, according to the size and thickness of
2.
3.
4.
5.
6.
the job.
Touch START
Open the connecting bridge cover.
Open the gathering area cover.
Put the set in the gathering area with the middle pages of the book face up.
Press the two buttons and hold for 9 seconds, or until you hear the folder operate.
The time interval changes according to the number of stitches.
47
Operate the Booklet maker offline
48
Chapter 4 Standard Tasks
Chapter 5
Error Conditions, Problems,
and Solutions
This chapter describes how to correct problems that can occur with your Booklet maker.
If a problem persists, contact your service engineer.
49
Clear a Printer Error
Clear a Printer Error
Introduction
If a paper jam or other error occurs in the printer, the printer and the Booklet maker
stop.
Procedure
1. Clear the printer error.
2. Follow the instructions on the printer. If the printer tells you to remove paper from
the Booklet maker, touch START to start the machine.
3. Then touch ADVANCED > PURGE SET > PURGE SET.
4. The partial book is delivered to the stacker.
5. Discard the book.
50
Chapter 5 Error Conditions, Problems, and Solutions
Clear a Booklet maker error
Clear a Booklet maker error
Introduction
If a paper jam or other error occurs in the Booklet maker, the printer and the Booklet
maker stop. The type of error is displayed on the touch screen (see ‘Error Messages’
on page 54).
Procedure
1. Clear the error. The error message on the touch screen tells you about the error.
2. Remove all sheets from the Booklet maker.
3. Follow the instructions on the printer.
51
General Problems
General Problems
[25]
Problem
Cause
Solution
The Booklet maker does
not start
The Booklet maker is not
turned on.
Turn ON the Booklet
maker (see ‘Turn ON the
Booklet maker’ on
page 13).
The printer has not sent a Correct the problem at the
job to the Booklet maker. printer.
The Booklet maker is not
connected to the power
supply.
Connect to the power
supply of the correct type
and voltage (see ‘Turn ON
the Booklet maker’ on
page 13)
A safety cover is open.
Close all safety covers.
The trim bin is not
Install the trim bin.
installed or the trim bin is
not installed correctly.
The START and STOP
buttons do not work
52
The Booklet maker is not
connected to the printer
interface.
Check the interface
cables. Connect the
cables.
A fuse has blown on the
power input.
Replace the fuse(s) as
needed (see ‘Change the
Fuses’ on page 85)
The stitch head is
jammed.
Clear the stitch head jam
and start the Booklet
maker again.Clear a
Stitch Head Jam on
page 80
An error condition exists
on the Booklet maker.
Check the error message
on the touch screen.
Correct the fault (see
‘Error Messages’ on
page 54)
The touch screen is in
power-save mode
Touch the touch screen to
restore normal function
The Touch Screen on
page 20.
Chapter 5 Error Conditions, Problems, and Solutions
General Problems
Problem
Cause
Solution
The operation of the
touch screen is incorrect
The touch screen is in
power-save mode
Touch the touch screen to
restore normal function
The Touch Screen on
page 20.
The touch screen
calibration is incorrect
Calibrate the touch screen
(see ‘Calibrate the Touch
Screen’ on page 84).
53
Error Messages
Error Messages
[26]
54
Problem
Cause
AXES MOVING
Some of the machine axes
are moving. This message
clears when the
adjustment is complete.
If the message does not
clear, touch ADVANCED
> RE REF
BOOK CYCLE TIME
TOO LONG
The printer has delivered
the sets faster than the
books can be made. To
decrease the book cycle
time, adjust the machine
settings:
■ decrease the number
of FORMS
■ decrease the number
of STITCHES
■ decrease the TAMPER
TIME
■ touch STOP to clear
the message from the
screen
Bridge axis moving
The bridge axis is
moving. This message
clears when the
adjustment is complete.
If the message does not
clear, touch ADVANCED
> RE REF.
BRIDGE INFEED
COVER OPEN
The bridge infeed cover is (see ‘Clear Paper Jams’
open.
on page 68)
The machine will not
operate until the cover is
closed.
Chapter 5 Error Conditions, Problems, and Solutions
Solution
Error Messages
Problem
Cause
Solution
BRIDGE MOTOR
STALL
Check for a paper jam in (see ‘Clear Paper Jams’
on page 68)
the connecting bridge.
■ Touch STOP to stop
the Booklet maker.
■ Clear the paper jam.
■ Touch STOP to clear
the message from the
screen.
■ Continue the print job.
CHECK THE TRIM BIN The trim bin is either open
or full. Check the trim
bin. Empty the trim bin if
necessary.
COVER OPEN
A safety cover is open.
The machine will not
operate until the cover is
closed.
DRIVE MOTOR STALL There is a paper jam.
Check the machine and
correct the error.
Touch STOP to clear the
message from the screen.
Endlay axis moving
The endlay axis (size
adjustment) is moving.
This message clears when
the adjustment is
complete.
If the message does not
clear, touch ADVANCED
> RE REF.
ERROR IN TRIM AREA There is an error at the
trimmer.
Check the trimmer for a
paper or book jam.
Touch STOP to clear the
message from the screen.
FLOW ERROR BRIDGE
There is an error at the
connecting bridge. Open
the connecting bridge
cover and check for a
paper jam.
(see ‘Clear Paper Jams’
on page 68)
55
Error Messages
56
Problem
Cause
Solution
FLOW ERROR FORMER
There is an error at the
former. Open the folder
cover and remove the
book(s). If necessary,
open the main deck to
remove the book(s).
If there is paper in the
gathering area, touch
START, then touch
ADVANCED > PURGE
SET > PURGE SET to
clear the set from the
machine.
Jam in the Folder or
Former Area on page 72
FLOW ERROR OUTFEED
There is an error at the
outfeed. Check the
outfeed. If necessary,
remove the trim bin and
open the trim stop guard
to remove the book(s).
Touch STOP to clear the
message from the screen.
If there is paper in the
gathering area, touch
START, then touch
ADVANCED > PURGE
SET > PURGE SET to
clear the set from the
machine.
Jam in the Trim Area on
page 74
Fold blade axis moving
The fold blade axis (book
thickness adjustment) is
moving. This message
clears when the
adjustment is complete.
If the message does not
clear, touch ADVANCED
> RE REF
FOLD BLADE NOT
PARKED
The fold blade is in the
wrong position. Touch
START to reset the
position. Follow the
instructions on the screen.
Chapter 5 Error Conditions, Problems, and Solutions
Error Messages
Problem
Cause
FORM CLAMP
CLOSED
The form clamp is in the
wrong position. Touch
START to reset the
position. Follow the
instructions on the screen.
FORM ROLLER ERROR The form roller is
jammed. Clear the jam
and continue.
Solution
(see ‘Jam in the Trim
Area’ on page 74)
FORM ROLLER NOT
PARKED
The form roller is in the
wrong position. Touch
START to reset the
position. Follow the
instructions on the screen.
GATHERING AREA
COVER OPEN
Close the gathering area
cover if you need to
operate the machine
online.
INVERTER ERROR
Check for a paper jam and
clear if necessary.
Touch STOP to clear the
message from the screen.
If the problem continues,
contact your service
engineer.
JAM AT BRIDGE
INFEED
There is a paper jam at the (see ‘Clear Paper Jams’
infeed to the connecting on page 68)
bridge. Clear the jam and
continue.
JAM AT FORM
ROLLER
The form roller is
(see ‘Jam in the Trim
jammed. Open the folder Area’ on page 74).
cover and remove the jam.
JAM BEFORE
TRIMMER
There is a book jammed
before the trimmer. Clear
the jam and continue.
JAM IN CONNECTING
BRIDGE
There is a paper jam in the (see ‘Jam in the
connecting bridge. Clear Connecting Bridge’ on
the jam and continue.
page 70)
(see ‘’ on page 73).
57
Error Messages
Problem
Cause
JAM IN GATHERING
AREA
There is a paper jam in the (see ‘Jam in the
gathering area. Open the Gathering Area’ on
connecting bridge cover, page 71)
lift the connecting bridge
and remove the paper
jam.
JAM IN STACKER
AREA
There is a paper jam at the
outfeed of the machine.
Remove the jammed
books and continue.
JAM IN STITCHER
AREA
There is a paper jam in the (see ‘Jam in the Stitch
stitch area. Open the
Area’ on page 72)
folder cover, remove the
paper jam and continue.
JAM IN STITCH HEAD
There is a jam in the stitch Clear a Stitch Head Jam
head.
on page 80
JAM IN TRIMMER
There is a book jammed
in the trimmer. Clear the
jam and continue.
MANUALLY PARK
SHUTTLE
The shuttle is not parked Manually park the Shuttle
correctly. Open the folder on page 86
cover and move the
shuttle to the park
position. Close the folder
cover. The shuttle will
reset. When the message
list is clear, continue
operation.
MISSING STITCHES
The machine has detected
missed stitches. Check to
see whether the
stitch-wire is jammed or
whether the stitch-wire
spool is empty.
MOTOR CONTROLLER The drive motor
NOT READY
controller is not ready. If
the problem continues,
contact your service
engineer.
58
Chapter 5 Error Conditions, Problems, and Solutions
Solution
(see ‘Jam in the Trim
Area’ on page 74)
(see ‘Clear a Stitch Wire
Jam’ on page 77)
(see ‘Install New Stitch
Wire’ on page 107)
Error Messages
Problem
Cause
REMOVE SET FROM
FOLD AREA
Open the folder cover and
remove the set.
REMOVE SET GATHERING AREA
Open the gathering area
and remove the sheets.
Or touch START, then
touch ADVANCED >
PURGE SET > PURGE
SET to clear the set from
the machine.
Rotate axis moving
The rotate axis is moving.
This message clears when
the adjustment is
complete.
If the message does not
clear, touch ADVANCED
> RE REF.
SET IN GATHERING
AREA
There is a set or partial set
in the gathering area.
If the print job has been
canceled, open the
gathering area and
remove the sheets. Or
touch START, then touch
ADVANCED > PURGE
SET > PURGE SET to
clear the set from the
machine.
Shuttle axis moving
The shuttle axis is
moving. This message
clears when the
adjustment is complete.
If the message does not
clear, touchADVANCED
> RE REF.
SHUTTLE MOTOR
COMMS FAIL
Use the ON/OFF switch.
Turn the machine OFF,
then turn the machine
ON. If the problem
continues, call your
service engineer.
Solution
59
Error Messages
60
Problem
Cause
SHUTTLE MOTOR
ERROR
Use the ON/OFF switch.
Turn the machine OFF,
then turn the machine
ON. If the problem
continues, call your
service engineer.
SHUTTLE NOT
PARKED
The shuttle is in the
wrong position. Touch
START to reset the
position.
Then touch STOP to clear
the message from the
screen.
Sidelay axis moving
The sidelay axis (size
adjustment) is adjusting.
This message clears when
the adjustment is
complete.
If the message does not
clear, touchADVANCED
> RE REF.
STACKER FULL
The stacker is full.
Unload the books from
the stacker.
Stitch axis moving
The stitch axis is moving.
This message clears when
the adjustment is
complete.
If the message does not
clear, touchADVANCED
> RE REF.
Stitch position adjusting
The stitch position is
adjusting. This message
clears when the
adjustment is complete.
If the message does not
clear, touchADVANCED
> RE REF.
Chapter 5 Error Conditions, Problems, and Solutions
Solution
Error Messages
Problem
Cause
Solution
STITCH TIMEOUT
There is an error at the
Stitch Timeout Error on
stitcher.
page 75
If the problem continues,
call your service engineer.
TOO MANY PAGES
The printer has delivered (see ‘Open the Gathering
more than 55 sheets into Area Cover’ on page 40)
the gathering area.
Remove the incorrect set.
Correct the printer
setting.
Touch STOP to clear the
message from the screen.
TOUCH PAD ERROR
There is a fault with the
START and STOP touch
pads. If the problem
continues, call your
service engineer.
Touch START to clear
machine
There may be some paper
in the machine. Touch
START to clear the
machine before you start
a new job.
Trim axis moving
The trim axis (size
adjustment) is moving.
This message clears when
the adjustment is
complete.
If the message does not
clear, touchADVANCED
> RE REF.
TRIM BIN OPEN
The trim bin is not
installed or is not in
contact with the safety
switch. Install the trim
bin.
61
Error Messages
62
Problem
Cause
TRIM BLADE NOT
PARKED
The trim blade is in the
wrong position. Touch
START to reset the
position.
Follow the instructions on
the screen.
USER STOP
The user has touched the
STOP button while the
machine is in operation.
Touch START to restart
the machine.
Chapter 5 Error Conditions, Problems, and Solutions
Solution
Book Quality
Book Quality
Paper Size and Book Quality Instructions
■
■
■
■
■
■
Careful measurement of the paper size and set thickness is important.
To make an accurate book you must enter accurate paper dimensions into the
touch screen.
Measure the size of the printed paper. The paper dimension changes when the
paper is printed.
If the book is made from several different types of paper, make sure the different
paper types are all the same size. If the size of the paper is different, an accurate
book cannot be made.
The paper must be cut accurately. If the sheets are not cut squarely, an accurate
book cannot be made.
Adjustments to the FORM settings can be necessary for some types of paper.
Machine Adjustments
Machine adjustments can be made while the machine is in operation. The PAPER
SIZE adjustment is limited to a maximum of +/- 1 mm when the machine is in
operation.
63
Book Quality
[27]
Book Quality
Problem
Cause
Solution
The finished book The wrong paper size was
Measure the paper and enter
is not neat and tidy entered on the touch screen. the correct dimensions (see
‘Enter the Job Settings’ on
The sheets are not
page 14).
aligned
The book is made from
Only use paper of the same
64
paper that is different sizes.
size (see ‘Paper Size and Book
Quality Instructions’ on
page 63).
The Booklet maker
adjustment system is not
calibrated correctly.
Touch RE-REF in the
ADVANCED window to
calibrate the Booklet maker
adjustment axes. (see table 11
on page 29)
The static elimination bars
are dirty.
Clean the static elimination
bars (see ‘Clean the Static
Elimination Bars’ on
page 92).
Incorrect function of the
static elimination bars.
Call your service engineer.
The spine is not
formed correctly
Incorrect settings.
(see ‘Spine Form Problems’
on page 66)
The book is not
trimmed
The TRIM function is not
selected.
Turn on the TRIM function.
See "TRIM" in table 9 on
page 25
The trim position is set
larger than the book.
Reset the trim position. See
"TRIM" in (see table 9 on
page 25)
The book is not
trimmed square
Trimmed paper has
collected on the trim stop.
Clear the trimmed paper from
the trim stop. (see ‘Jam in the
Trim Area’ on page 74)
The trimmed edge
is of bad quality
The trimmer blade is blunt
or damaged.
Call your service engineer.
Chapter 5 Error Conditions, Problems, and Solutions
Book Quality
Book Quality
Problem
Cause
The stitch is not on The wrong paper size was
the center-line of
entered on the touch screen.
the spine
The Booklet maker
adjustment system is not
calibrated correctly.
Solution
Measure the paper and enter
the correct dimensions.
Touch RE-REF in the
ADVANCED window to
calibrate the Booklet maker
adjustment axes. (see table 11
on page 29)
The books do not
stack on the
stacker
The collection table is in the Adjust the position of the
wrong position.
collection table to fit the size
of the finished book. Adjust
the Stacker on page 45
The book cover is
dirty or marked
The former roller is dirty.
Clean the former roller (see
‘Clean the Former Roller’ on
page 94).
[23]
Marks on the spine
The former clamp is dirty.
Clean the Polyurethane Strips
in the Form Clamp on page 96
[24]
Marks beside the spine
65
Book Quality
Book Quality
Problem
Cause
Solution
The book cover is
dirty or marked
The trimmings-removal
fingers are dirty.
Clean the Trimmings Removal
Fingers on page 98
Curved marks on the book
There are grease marks
around the stitches.
Clean excess grease from the
Stitch Head on page 101
[25]
[26]
Grease marks near the stitches
Spine Form Problems
To make the square spine of the book, pressure is applied to the spine. This process
is called forming. The Booklet maker automatically applies the optimum amount of
form according to the book thickness.
Some types of paper may need further adjustment.
[28]
Spine Form
[27]
66
Condition
Correct
The spine is square at each end and the paper is not
damaged.
The Booklet maker setting is correct. Adjustment is
not needed.
Chapter 5 Error Conditions, Problems, and Solutions
Book Quality
Spine Form
[28]
Condition
Incorrect - The spine needs more form.
Check these settings:
The SET THICKNESS
setting is incorrect
Measure the set thickness
and enter the correct
dimension. Enter the Job
Settings on page 14
The folder cover is not
securely closed?
Close the folder
cover.Close the Folder
Cover on page 37
The FORM function is
not turned on?
Turn on the FORM
function. See "FORM" in
table 9 on page 25
The THRESHOLD
Decrease the
value is less than the SET THRESHOLD value.
THICKNESS?
See THRESHOLD
table 9 on page 25
Does the spine need more Change NUMBER to 2
form at one end?
or 4. See "FORM" in
table 9 on page 25
Does the spine need more Increase PRESSURE.
form at each end?
Then, if the spine still
needs more form,
increase NUMBER. See
"FORM" in table 9 on
page 25
[29]
Incorrect - The spine is damaged or there are
creases near the spine.
Check these settings:
The SET THICKNESS
setting is incorrect?
Measure the set thickness
and enter the correct
dimension. Enter the Job
Settings on page 14
The spine of the book
needs less forming.
Decrease PRESSURE.
Then, if the spine is still
over formed, decrease
NUMBER. See "FORM"
in table 9 on page 25
67
Clear Paper Jams
Clear Paper Jams
Introduction
[30]
A
B
C
D
E
[30] Paper Jam Locations
[29]
A
Connecting Bridge
B
Gathering Area
C
Stitch Area
D
Fold and Forming Areas
E
Trim Area
[31]
A
[31] Paper Jam Location - Bridge Infeed
68
Chapter 5 Error Conditions, Problems, and Solutions
Clear Paper Jams
[30]
A
Bridge Infeed Cover
[32]
A
B
[32] Trimmer Infeed Conveyor viewed from above.
Jam before the Trimmer on page 72
[31]
A
Trimmer Infeed Conveyor
B
Former-clamp mechanism
[33]
A
B
C
[33] Trim Stop Assembly
Jam in the Trim Area on page 74
69
Clear Paper Jams
[32]
A
Orange Plastic Hand Screw
B
Locking Plate
C
Trim Stop Guard
[34]
[34] Gathering Area Belt Positions
Jam in the Bridge Infeed
Open the bridge infeed cover.
Remove the jammed paper.
Close the bridge infeed cover.
Touch STOP
to clear the message from the screen.
If there is paper in the gathering area, touch START
, then touch ADVANCED
> PURGE SET > PURGE SET to clear the set from the machine.
6. Continue the print job.
1.
2.
3.
4.
5.
Jam in the Connecting Bridge
1.
2.
3.
4.
70
Open the connecting bridge cover.
Remove the jammed paper. Do not damage or move the belts.
Close the connecting bridge cover.
Touch STOP
to clear the message from the screen.
Chapter 5 Error Conditions, Problems, and Solutions
Clear Paper Jams
5. If there is paper in the gathering area, touch START
, then touch ADVANCED
> PURGE SET > PURGE SET to clear the set from the machine.
6. Continue the print job.
Jam in the Gathering Area
1.
2.
3.
4.
5.
6.
7.
8.
Open the connecting bridge cover.
Lift the gathering area cover.
Remove the jammed paper.
Check the belts are in the correct position. Adjust the position of the belts if
necessary. figure 34 on page 70
Close the gathering area cover.
Close the connecting bridge cover.
Touch STOP
to clear the message from the screen.
Continue the print job.
71
Clear Paper Jams
Jam in the Stitch Area
[33]
Step
Action
Information
1
Open the folder cover.
(see ‘Open and Close the Folder
Cover’ on page 37)
2
Lift the clincher frame.
(see ‘Lift and Lower the Clincher
Frame’ on page 38).
3
Remove the jammed paper.
4
Check for broken or damaged
stitches in the clincher area.
A
Manually operate the clincher
to clear any stitches that are
jammed.
Press to manually operate the
clincher.
Lower the clincher frame.
(see ‘Lift and Lower the Clincher
Frame’ on page 38)
5
[35]
6
Close the folder cover.
7
If there is paper in the
gathering area, touch START,
then touch ADVANCED >
PURGE SET > PURGE
SET.
8
Continue the print job.
This action clears paper from the
BLM 500 / Bookletmaker 50.
Jam in the Folder or Former Area
1. Open the folder cover.
2. Remove the jammed paper. If you cannot see the paper in the former area. (see ‘Jam
in the Trim Area’ on page 74)
3. Close the folder cover.
4. If there is paper in the gathering area, touch START
, then touch ADVANCED >
PURGE SET > PURGE SET to clear the set from the machine.
5. Continue the print job.
Jam before the Trimmer
The error message JAM BEFORE TRIMMER is displayed. This error can be
1. a book jammed before the trimmer
2. a piece of paper trimming has covered the jam sensor
72
Chapter 5 Error Conditions, Problems, and Solutions
Clear Paper Jams
[34]
Step
Action
1
Open the Booklet maker main
deck
2
Remove the trim bin.
3
Loosen the trimmer infeed
conveyor.
Information
The procedure can be seen from
the top of the machine. Access to
the parts is through the
former-clamp mechanism. Hold
the shaft and push to the right,
against the spring pressure.
Hold the shaft and push to the
right, against the spring pressure to
disengage the shaft from the drive
pin.
[36]
Lift the left-hand end clear.
4
Remove the book, if one is
found.
5
Remove any paper offcuts
from the trimmer infeed
conveyor.
A small piece of paper can cover
the jam sensor and cause an error
message.
6
Install the trimmer infeed
conveyor.
Insert the right-hand end of the
shaft into the bearing, against the
spring pressure. Insert the
left-hand end.
7
Install the trim bin.
8
Close the Booklet maker main
deck and covers.
9
If there is paper in the
gathering area, touch START,
then touch ADVANCED >
PURGE SET > PURGE
SET.
10
Continue the print job.
This action clears paper from the
Booklet maker.
73
Clear Paper Jams
Jam in the Trim Area
[35]
74
Step
Action
Information
1
Remove the trim bin.
2
Loosen the 2 orange plastic
hand screws to release the
locking plates.
3
Pull the trim stop guard
towards you.
4
Remove the jammed book.
5
Push the trim stop guard into
position.
6
Hold the locking plates in
position and tighten the orange
hand screws.
7
Attach the trim bin.
8
Touch START, then touch
This action clears any other paper
ADVANCED > PURGE SET from the Booklet maker.
> PURGE SET.
9
Continue the print job.
The locking plates can rotate to
release the trim stop guard.
Check the trim stop and remove
any pieces of trimmed paper.
Chapter 5 Error Conditions, Problems, and Solutions
Stitch Timeout Error
Stitch Timeout Error
Introduction
[36]
Step
Action
Information
1
Open the folder cover.
Open and Close the Folder Cover
on page 37
2
Lift the clincher frame.
Lift and Lower the Clincher Frame
on page 38
3
Remove the paper.
4
Lower the clincher frame.
5
Close the folder cover.
6
If the error message
SHUTTLE NOT PARKED is
displayed, touch START
7
Touch STOP
and then
continue the print job.
Lift and Lower the Clincher Frame
on page 38
This action moves the shuttle to the
correct position.
75
Stitch Head Problems
Stitch Head Problems
[37]
Problem
Cause
Solution
The stitch head does not
operate
The STITCH function is
not selected.
Make sure STITCH is set
to 1 or more (see ‘The
BASIC Window’ on
page 25).
The stitch wire is
finished.
Load a new spool of
stitch-wire (see ‘Install
New Stitch Wire’ on
page 107).
The stitch wire is
jammed.
Clear the jammed stitch
wire (see ‘Clear a Stitch
Wire Jam’ on page 77).
The stitches are broken
There is stitch wire
Inspect and remove the
jammed in the stitch head. jammed stitch wire (see
‘Clear a Stitch Wire Jam’
on page 77).
The stitch wire is jammed The stitch wire spool is
on the spool
not installed correctly.
76
Chapter 5 Error Conditions, Problems, and Solutions
Check and correct (see
‘Fit a New Stitch Wire
Spool’ on page 108).
Clear a Stitch Wire Jam
Clear a Stitch Wire Jam
Introduction
Before you begin:
Lift the Booklet maker main deck. See Lift the Booklet maker Main Deck on page 41
[37]
A
B
C
D
[37] Stitch Head.
77
Clear a Stitch Wire Jam
[38]
A
Top location of Middle Wire Tube
B
Middle Wire Tube
C
Metal Spring Clip
D
Feed Gears
Before You Begin
[39]
Step
Action
Information
1
Turn off the Booklet maker
Use the ON/OFF switch.
2
Disconnect the Booklet maker
from the power supply.
3
Lift the Booklet maker main
deck
(see ‘Lift the Booklet maker Main
Deck’ on page 41)
Clear the Jammed Wire
[40]
Step
1
Action
Cut the stitch wire at position
'A' approximately 50mm (2
inches) from where the stitch
wire leaves the stitch wire
guide.
Information
[38]
A
Detail A: Cut stitch wire here.
2
Cut the stitch wire at position
'B' between the feed gears
and the middle wire tube.
[39]
B
Detail B: Cut stitch wire here.
3
Pull the stitch wire from the
stitch wire guide block.
[40]
Pull stitch wire in direction of arrow
78
Chapter 5 Error Conditions, Problems, and Solutions
Clear a Stitch Wire Jam
Step
Action
Information
Remove the middle wire
tube.
figure 37 on page 77
Pull the wire from the stitch
head.
5
Install the stitch wire into the (see ‘Install the Stitch Wire into the
stitch head.
Stitch Head’ on page 110)
79
Clear a Stitch Head Jam
Clear a Stitch Head Jam
Introduction
The error message JAM IN STITCH HEAD is displayed.
This may be caused by
■
■
■
the SET THICKNESS setting is incorrect
the stitch head is jammed by broken wire
the stitch head needs lubrication
Do Procedure 1. If the error message continues, do Procedure 2.
80
Chapter 5 Error Conditions, Problems, and Solutions
Clear a Stitch Head Jam
Procedure 1
[41]
Step
Action
Information
1
Stop the Booklet maker.
Touch the STOP button
2
Open the folder cover.
Open and Close the Folder Cover
on page 37
3
Lift the clincher frame.
Lift and Lower the Clincher Frame
on page 38.
4
Remove the jammed paper.
5
Check for broken or damaged
stitches in the clincher area.
A
Manually operate the clincher
to clear any stitches that are
jammed.
Press to manually operate the
clincher.
Lower the clincher frame.
Lift and Lower the Clincher Frame
on page 38
6
[41]
7
Close the folder cover.
8
If there is paper in the
gathering area, touch START,
then touchADVANCED >
PURGE SET > MAKE
BOOK.
9
Continue the print job.
This action clears paper from the
BLM 500 / Bookletmaker 50and
resets the stitch head.
Procedure 2
[42]
[42]
A
B
C
[42] Remove the stitch head wire holder
A
Stitch head
81
Clear a Stitch Head Jam
B
Wire holder
C
Wire holder retaining spring
[43]
[43]
A
[43] Inspect for stitch wire
A
Inspect this area for pieces of stitch wire
Tools and Materials:
1.
2.
3.
4.
82
Klüber Isoflex NBU 15 Grease, 50g.
Air duster. Supplied with the machine
Wire cutters. Supplied with the machine.
Flat blade screwdriver.
Chapter 5 Error Conditions, Problems, and Solutions
Clear a Stitch Head Jam
[44]
Step
Action
Information
1
Lift the Booklet maker main
deck.
See Lift the Booklet maker Main Deck
on page 41
2
Remove the wire-holder
from the stitch head.
■
■
Move the wire-holder retaining
spring to the right. figure 42 on
page 81
Remove the wire-holder
If the wire-holder is held in position,
use a screwdriver to help remove the
wire-holder from the stitch head.
[44]
3
Inspect the area behind the
wire-holder for stitch-wire.
figure 43 on page 82
4
Remove any stitches or
pieces of stitch-wire and
clean the area with the air
duster.
Use wire cutters to remove any
jammed stitches or pieces of
stitch-wire.
5
Lubricate the stitch-head.
Lubricate the Stitch Head on
page 102
6
Fit the wire-holder.
Remember to put the wire-holder
retaining spring in position.
7
Close the Booklet maker.
8
Start the Booklet maker.
If the head operates normally and
returns to the parked position, then
further action is not needed.
If the stitch-head remains jammed,
then repeat the procedure again.
If the problem continues, contact
your service engineer.
83
Calibrate the Touch Screen
Calibrate the Touch Screen
When to do
Calibrate the touch screen if the buttons do not operate or the buttons do not operate
correctly.
Attention: Use a pencil, the blunt end of a pen or a palm top wand for this
procedure. Do not use a sharp object. Sharp objects damage the screen.
Procedure
1. Touch the STOP button
5 times.
2. Follow the instructions on the touch screen.
3. Touch DONE in the centre of the screen.
84
Chapter 5 Error Conditions, Problems, and Solutions
Change the Fuses
Change the Fuses
Introduction
The Booklet maker has two fuses at the power input. If either fuse is blown, the
Booklet maker will not operate.
Required tool
Fuse description: 7A, HRC Quick Acting, F
Attention: Turn OFF the machine and remove the power supply cable before
you change the fuses. This machine uses two fuses in parallel. To avoid the risk
of fire, replace fuses only with the same type and rating.
Procedure
1.
2.
3.
4.
5.
6.
Turn OFF the Booklet maker.
Disconnect the Booklet maker from the power supply.
Turn one fuse-holder to the left and remove the fuse-holder from the Booklet maker.
Check the fuse.
If the fuse is blown, then replace with a fuse of the correct specification.
Repeat the procedure for the other fuse.
Note: If the fuse blows again, call your service engineer.
85
Manually park the Shuttle
Manually park the Shuttle
When to do
The error messages ‘MANUALLY PARK SHUTTLE’ and ‘SHUTTLE NOT
PARKED’ are displayed.
Illustration
[45]
[45] Shuttle Assembly Position - CORRECT
[46]
[46] Shuttle Assembly Position - NOT CORRECT
[47]
A
[47] Detail A: Pick-up fingers
86
Chapter 5 Error Conditions, Problems, and Solutions
Manually park the Shuttle
[45]
Step
1
Open the folder cover.
Open and Close the Folder Cover
on page 37
2
Push the shuttle-assembly to
the right.
figure 45 on page 86 shows the
correct position for the shuttle
assembly.
If the shuttle assembly does not
move to the correct position, push
the pick-up fingers away from each
other by 2-3mm and try again.
Repeat if necessary.
3
Wait until the error message
‘SHUTTLE NOT PARKED’
is cleared from the screen.
If the message does not clear, check
that the shuttle assembly is in the
correct position. Repeat Step 2 if
necessary.
4
Close the folder cover.
Result
The error message ‘MANUALLY PARK SHUTTLE’ is cleared from the screen.
The shuttle axis re-references and the message ‘Shuttle axis moving’ is displayed.
When the message list is clear, you can continue operation
87
Manually park the Shuttle
88
Chapter 5 Error Conditions, Problems, and Solutions
Chapter 6
Maintenance
89
About Maintenance
About Maintenance
Service Interval
The Booklet maker needs service every four months.
After every one million stitches, the stitch head needs service. This interval is
every third spool of stitch-wire.
■
■
Only a service engineer can service the Booklet maker. Contact your supplier for
further information.
Operator Maintenance
Correct maintenance by the operator makes sure that
■ The machine operates correctly
■ The machine makes high-quality books
■ The machine is safe to use
■ Small problems can be identified early
Operator Maintenance Plan
[46]
Interval
■
Every week
Task
Reference
Clean the machine.
(see ‘Booklet maker
cleaning’ on page 91)
Clean the static elimination (see ‘Clean the Static
bars.
Elimination Bars’ on
page 92)
■
■
90
Every month, or
When a new stitch
wire is installed if
this interval is
shorter.
Chapter 6 Maintenance
Lubricate the stitch head.
(see ‘Lubricate the Stitch
Head’ on page 102)
Booklet maker cleaning
Booklet maker cleaning
Introduction
Clean the Booklet maker every week to remove surface dust.
Attention: Only clean the machine with materials that are recommended in this
manual. Do not use other chemicals or abrasive material.
Outside of the Booklet maker
Use a moist cloth to clean the outside of the Booklet maker.
Touch screen
Clean the touch screen with a clean, dry cloth. Never use an abrasive material or
chemical to clean the touch screen. Light pressure with a clean, dry cloth is enough
to remove fingerprints. Do not use too much force.
91
Clean the Static Elimination Bars
Clean the Static Elimination Bars
Introduction
Clean the static elimination bars every week. This action extends the performance
and service life of the static elimination bars.
The Booklet maker is supplied with a small brush. Use the brush to clean the static
elimination bars.
There are three static elimination bars.
■ One in the connecting bridge
■ Two in the gathering area
[48]
A
[48] The Static Elimination Bars in the Gathering Area
[49]
A
[49] The Static Elimination Bar in the Connecting Bridge
[47]
A
Static Elimination Bars
Note: On the bottom of the static elimination bar there is a row of sharp pins. The
pins are not dangerous, but if you touch the pins accidentally, this action can alarm
you.
92
Chapter 6 Maintenance
Clean the Static Elimination Bars
[48]
Step
Action
Information
1
Clean the static elimination bar
in the connecting bridge.
■
■
2
3
Clean the static elimination
bars in the gathering area.
■
Close the Booklet maker.
■
■
■
Open the connecting bridge
cover.
Clean the pins on the bottom of
the static elimination bar with a
small brush
Open the gathering area cover.
Clean the pins on the bottom of
the static elimination bars with a
small brush
Close the gathering area cover
Close the connecting bridge
cover.
93
Clean the Former Roller
Clean the Former Roller
Introduction
Clean the former roller if the spines of the books are dirty. Ink and toner can collect
on the former roller.
[50]
[50] Dirty marks on the spine
Required tool
Clean, plain paper that is not printed. A3 size (USA: 11 x 17”) is recommended.
4mm thickness is needed for each cycle. More than one cycle can be needed
94
Chapter 6 Maintenance
Clean the Former Roller
Procedure
[49]
Step
Action
Information
1
Enter the correct settings on
the touch screen.
■
■
■
■
2
Touch START
3
Open the connecting bridge
cover.
4
Lift the gathering area cover.
5
Put 4mm of clean paper in the
gathering area.
6
Press the two orange buttons
and hold for 9 seconds, or until
you hear the folder operate.
Set the touch screen to the
correct PAPER SIZE
Set the SET THICKNESS to
4.0
Set the number of STITCHES
to 0.
Set the number of FORMS to
4.
Result
The book is delivered to the stacker. Check the book. Repeat the procedure until the
book spine is clean.
95
Clean the Polyurethane Strips in the Form Clamp
Clean the Polyurethane Strips in the Form Clamp
Introduction
Follow this procedure if there are dirty marks near the spine on the front and back
cover of the book. Ink and toner can collect on these parts, especially when you make
thin books.
[51]
[51] Dirty marks beside the spine
Required tools
Alcohol wipe or
A lint free cloth and alcohol (isopropanol)
Caution: Only use alcohol to clean this part of the machine. Other
chemicals can damage the machine.
Note: If you push the eject rollers, the rollers can move together against your hand.
This movement can alarm you, but is not dangerous.
Illustration
[52]
A
[52] Detail A: Polyurethane strips
96
Chapter 6 Maintenance
Clean the Polyurethane Strips in the Form Clamp
[50]
Step
Action
1
Open the folder cover
2
Use an alcohol wipe, or apply a
small amount of alcohol to a
lint free cloth.
3
Reach into the form clamp and
clean each of the polyurethane
strips.
4
Close the folder cover
Information
There is a polyurethane strip on the
face of each side of the clamp.
Repeat this step until the
polyurethane strips are clean.
97
Clean the Trimmings Removal Fingers
Clean the Trimmings Removal Fingers
Introduction
Follow this procedure if there are small, dirty marks on the book. Ink and toner can
collect on the trimmings removal fingers and cause marks on the book.
[53]
[53] Curved marks on the book
Required tool
Alcohol wipe
98
Chapter 6 Maintenance
Clean the Trimmings Removal Fingers
Illustration
[54]
A
B
[51]
A
Trimmer infeed conveyor
B
Former clamp mechanism
Illustration
[55]
A
B
C
[52]
A
Trimmer infeed conveyor
B
Trimmings removal fingers
C
Former clamp mechanism
Illustration
[56]
A
B
99
Clean the Trimmings Removal Fingers
[53]
A
Trimmings removal fingers
B
Drive end of the conveyor shaft
Procedure
[54]
Step
Action
1
Turn off the Booklet maker
2
Lift the Booklet maker main
deck.
3
Remove the trim bin.
4
Clean the visible
trimmings-removal fingers
with an alcohol wipe.
5
Rotate the conveyor shaft by
half a turn.
Information
The procedure can be seen from the
top of the machine. Access to the
parts is through the former-clamp
mechanism.
1. Hold the shaft and push to the
right, against the spring pressure to
disengage the shaft from the drive
pin.
[57]
1
2
3
2. Rotate the shaft by half a turn.
3. Align the shaft with the drive pin
and release.
100
6
Clean the visible
trimmings-removal fingers
with an alcohol wipe.
7
Install the trim bin.
8
Close the Booklet maker.
Chapter 6 Maintenance
Clean excess grease from the Stitch Head
Clean excess grease from the Stitch Head
Introduction
Follow this procedure if there are grease marks around the stitches on the book.
[58]
Required tool
Lint free cloth
Procedure
[55]
Step
Action
Information
1
On the user interface, touch
ADVANCED > STITCHER
UP > STITCHER UP
The folder cover must be closed.
This action moves the stitch head to
the correct position for lubrication.
2
Open the folder cover.
Open and Close the Folder Cover
on page 37
3
Lift the clincher frame.
Lift and Lower the Clincher Frame
on page 38
4
Clean grease from the sides of
the stitch head.
5
Lower the clincher frame.
6
Close the folder cover.
[59]
101
Lubricate the Stitch Head
Lubricate the Stitch Head
Introduction
[60]
[60] Trim the nozzle of the tube of grease
[61]
A
B
C
[61] Stitch Head Wire Holder
102
Chapter 6 Maintenance
Lubricate the Stitch Head
[56]
A
Stitch Head
B
Wire Holder
C
Wire Holder Retaining Spring
[62]
A
B
[62] Driver Bar
[57]
A
Driver, in upper position
B
Driver Bar
Required tools
Klüber Isoflex NBU15 Grease, 50g
Air duster - is supplied with the machine
Attention: - Only use the grease shown in this manual. Correct lubrication
extends the performance and service life of the stitch head. Other types of grease
do not protect the stitch head
- Only apply the grease as shown. If you apply additional grease, the paper gets
marked.
103
Lubricate the Stitch Head
Before You Begin
[58]
Step
Action
Information
1.
Trim the first part from the
nozzle.
figure 60 on page 102
2.
Remove the cap from the tube
of grease.
3.
Fit the nozzle to the tube of
grease.
4.
On the user interface, touch
ADVANCED > STITCHER
UP > STITCHER UP
The folder cover must be
closed. This action moves the
stitch head to the correct
position for lubrication.
5.
Lift the Booklet maker main
deck
See Lift the Booklet maker
Main Deck on page 41
Apply Grease to the Driver Bar
[59]
104
Step
Action
1
Use the supplied air duster to
remove dust from the stitch
head.
2
Remove the wire-holder from Move the wire-holder retaining spring
the stitch head.
to the right. Then remove the
wire-holder (see Introduction on
page 102)
Chapter 6 Maintenance
Information
Lubricate the Stitch Head
Step
Action
Information
3
Apply 30 mm of grease to the figure 62 on page 103
visible surface of the driver
bar
[63]
1.2"
[64]
4
Re-fit the wire-holder.
5
Lower the Booklet maker
main deck.
6
Lower the clincher frame.
7
Close all of the covers.
(see ‘Lower the Clincher Frame’ on
page 39).
105
Lubricate the Wire-feed Cam
Lubricate the Wire-feed Cam
Introduction
[65]
A
B
C
[65] Lubricate the wire-feed cam
[60]
A
Nozzle for the tube of grease
B
Wire-feed cam
C
Feed lever
Lubricate the wire-feed cam
[61]
Step
Action
1.
Lift the PSQ main deck.
2.
Apply 10 mm of grease from
the tube between the bearing
surface of the wire-feed cam
and the feed lever.
Information
figure 65
[66]
0.4"
106
3.
Lower the Booklet maker main
deck
4.
Lower the clincher frame.
5.
Close all of the covers
Chapter 6 Maintenance
Lower the Clincher Frame on
page 39
Install New Stitch Wire
Install New Stitch Wire
Introduction
Only use stitch-wire that is approved by your supplier. Stitch-wire that is not
approved by your supplier can cause poor performance and voids the warranty.
Stitch-wire Description: Stitcher wire S33.
Before you begin
Lift the Booklet maker main deck.
See (see ‘Lift the Booklet maker Main Deck’ on page 41)
Illustration
[67]
A
B
C
[67] Stitch Wire Guide Block
107
Install New Stitch Wire
[62]
A
Stitch Wire Guide Block
B
Stitch wire
C
Felt wire-cleaning pads
Remove the Stitch Wire from the Stitch Head
[63]
Step
1
Action
Cut the stitch wire to the right
of the stitch wire guide block.
Information
[68]
A
Detail A: Cut here
2
Pull the stitch wire from the
stitch wire guide block.
3
Fit a new stitch wire spool.
(see ‘Fit a New Stitch Wire Spool’)
Fit a New Stitch Wire Spool
[64]
108
Step
Action
1
Open the stitch wire cabinet
2
Remove the stitch wire cap
and finished stitch wire spool.
3
Fit a new stitch wire spool.
4
Fit the stitch wire cap
5
Loosen the end of the stitch
wire from the edge of the
stitch wire spool.
Chapter 6 Maintenance
Information
[69]
Install New Stitch Wire
Step
Action
Information
6
Use wire cutters to remove the Remove enough stitch wire to leave
damaged end of the stitch
the end of the stitch wire clean and
wire.
straight.
7
Feed the stitch wire through
the stitch wire guide.
8
Install the stitch wire.
[70]
(see ‘Install the Stitch Wire into the
Stitch Head’ on page 110)
109
Install New Stitch Wire
Install the Stitch Wire into the Stitch Head
[65]
Step
Action
1
Pull the stitch wire from the
end of the stitch wire guide.
2
Make sure the stitch wire runs
behind the gas-strut.
3
Feed the end of the stitch wire
between the felt
wire-cleaning pads.
Information
[71]
[72]
A
Detail A: Felt Wire-Cleaning Pads
4
Push the stitch wire into the
stitch wire guide block.
5
Push the stitch wire as far as
possible.
[73]
Push stitch wire in direction of arrow
[74]
A
Detail A:Make sure the stitch wire runs
between the wire feed rollers and into
the middle wire tube.
Close the Booklet maker
[66]
110
Step
Action
1
Close the stitch-wire cabinet.
2
Lower the Booklet maker
main deck.
3
Lower the clincher frame.
Chapter 6 Maintenance
Information
(see ‘Lower the Clincher Frame’ on
page 39).
Install New Stitch Wire
Step
Action
4
Close the folder cover.
5
Close the connecting bridge
cover.
Information
Feed the Stitch-wire
[67]
Step
Action
Information
1
Touch START.
3
Set the number of stitches to 6 Touch BASIC > STITCHES.
4
Hand-feed or print an A4 or
larger size test job.
The stitch-wire loads automatically
during the stitch head cycle.
5
Check that the stitch-wire is
loaded.
Check that a stitch is made. If needed,
repeat the previous step.
If a stitch is still not made, repeat the
procedure. Install the stitch-wire into
the stitch head Install the Stitch Wire
into the Stitch Head on page 110.
6
Reset the number of stitches
on the touch screen.
111
Install New Stitch Wire
112
Chapter 6 Maintenance
Appendix A
Specifications
113
Specifications
Specifications
[68]
Operating
Conditions
10-35°C at 35-85% relative humidity
Production
Cycle time: Printer dependent
Interset gap: 2 seconds (if printer has DFD2, then 1.5 or
2 seconds, depending on job settings)
Minimum set time: 7.5 seconds (if printer has DFD2,
then 5.5 or 7.8 seconds, depending on job settings)
Maximum set time: 12.5 seconds
Stock Sizes
Minimum input size: 203 x 203 mm
Maximum input size: 320 x 488 mm
[75]
A
8" x 8"
12.6" x 19.2"
B
A = Stitch & fold line
B = indicates original lead edge from the printer
Sheet Rotation
Integrated rotator ensures maximum printer productivity.
Maximum rotation sheet size: 320 x 227 mm
Minimum rotation sheet size: 210 x 203 mm
The cross-track dimension of the sheet (before rotation)
must be at least 7 mm greater than the in-track
dimension.
8.3"
[76]
A
8"
12.6" x 8.9"
B
A = Stitch & fold line
B = indicates original lead edge from the printer
Stock Range
114
Appendix A Specifications
80 - 160gsm normal paper types
70 - 250gsm dependant on paper type and quality
Specifications
Book Thickness
Maximum finished book thickness: 10 mm
(approximately 200 pages 80gsm)
Maximum set thickness: 5 mm (approximately 50 sheets
80gsm)
Stitching
1 - 6 stitches, evenly spaced on the spine of the book
Stitches/spool: up to 291,500
Books*/spool: approximately 127,000
Trimming
Maximum fore-edge trim: 28 mm
Minimum trimmed book size: 80 mm
[77]
min. ± 3.2"
max. ±1.1"
† Serial no. 22 onwards
Stacker Capacity
35 books*
Paper Input
Requirements
Input sheets must be of consistent size and cut square.
Machine setting must match paper size at the input to the
Booklet maker
Book quality is dependent upon the quality of the input
sheets.
Dimensions
Footprint: 1870 x 1675 mm
Height - 1330 mm maximum
Weight
Booklet maker including stitching wire: 542kg
As per above, plus bridge and bridge covers: 702kg
Power Supply
Adjustable to 200, 208, 220, 230 and 240V
50/60Hz, single phase
Power Consumption
stand-by: 92VA (75W)
in operation: 700VA (500W)
Noise Emission
stand-by: ambient
in operation: 66 dB (A), peak 87 dB (A)
Approvals
Complies with CE and UL. Conforms to FCC rules Part
15 Class A.
* Standard book is made from 20 sheets of 80gsm paper, with 2 stitches.
Production may vary according to operating conditions. In line with a policy of
continual product improvement, the manufacturer reserves the right to alter the
materials or specifications of this product at any time without notice.
115
Specifications
116
Appendix A Specifications
Appendix B
Declaration of Conformity
117
Declaration of Conformity
Declaration of Conformity
[69]
Name of
Manufacturer:
Watkiss Automation Limited
Address of
Manufacturer:
Watkiss House
Blaydon Road
Sandy, Bedfordshire
SG19 1RZ
United Kingdom
Declares that the product:
Name of Product:
BLM 500 / Bookletmaker 50
serial Number:
WA/PSQ/---/010 onwards
Conforms to the following Directives:
Safety:
290/95/EEC Council Directive 'on the approximation of
laws of Member States relating to electrical equipment
designed for use within certain voltage limits'.
BS EN 60950 : 2002
EMC:
89/336/EEC Council Directive 'on the approximation of
laws of Member States relating to electromagnetic
compatibility'.
EN55022:1998 Class A
EN55024:1998
EN61000-3-2:2000 + A2:2005
EN61000-3-3:1995 + A1:2001
M C Watkiss
Technical Director
Watkiss Automation Ltd.
January 2, 2007
118
Appendix B Declaration of Conformity